INSTALLATION, OPERATION & MAINTENANCE MANUAL (IOM) 12-16 ISO Registered Company MODEL SCV-S GLOBE-STYLE - SANITARY PNEUMATIC CONTROL VALVE BODY IOM SECTION I I. DESCRIPTION AND SCOPE Model SCV-S is a pneumatically actuated, globe-style con trol valve for throttling sanitary or biotechnological ap pli ca tions. The globe body comes in two variations - straight-globe pattern and angle-globe pattern, sizes 3/4" - 1-1/2" (DN20 - DN40) with standard Tri-Clover sanitary end connections. The valve is available in either a metal or composition seat construction. The wetted metallic body portion is of forged 316L SST mechanically and electro-polished to a 10 micro-inch R a finish. A field reversible actuator, Model C27 is mounted to the body. Failure position is determined by actuator for: "D" = Direct action; on increasing air loading pressure, the actuator stem extends. Fail-safe position is with the stem retracted. "R" = Reverse action; on increasing air loading pressure, the actuator stem retracts. Fail-safe position is with the stem extended. The standard actuator stem-to-valve stem connection is a screwed joint design; Opt.-68 Quick Disconnect Joint is also available. II. REFERENCE SECTION II Straight Body Pattern with ATC - FO Actuator ABBREVIATIONS Refer to Technical Bulletin SCV-S-TB for complete tech ni cal specifications. www.cashco.com/techbulletins/scvs.pdf Refer to following Installation, Operation & Main te nance Manuals (IOM s) for the actuator and/or devices that maybe mounted to a Model SCV-S: Actuators: www.cashco.com/iom/c27-c53.pdf ATC-FO - Air to Close, Fail Open ATO-FC - Air to Open, Fail Close CCW - Counter-Clockwise CIP - Clean-in-Place CW - Clockwise DIR - Direct Acting IAS - Instrument Air Supply REV - Reverse Acting SIG - Output Signal from Instrument SIP - Steam-in-Place V - Vent
SECTION III III. OPERATION CONSIDERATIONS A. Clean-in-Place (CIP): 1. Control valve unit must be properly oriented per Sec tion IV.A. to assure self-draining of valve s internal pas sag es. 2. Control valve unit comes in the direct action, ATC-FO arrangement or the reverse action, ATO-FC ar range ment. Valve should be in the full open po si tion before initiation of the CIP pro ce dure. Control system must ac com mo date this ca pa bil i ty. 3. Cleaning fluid may flow in either direction. 4. Cleaning fluid pressure must not exceed 50 psig (3.4 Barg). 5. Cleaning fluid temperature must not exceed 366 F (186 C). 6. Cleaning fluid must be compatible with wetted ma te ri als. B. Steam-in-Place (SIP): 1. Orientation to be same as CIP,Section III.A.1. 2. Steam may flow from either direction. 3. Recommended 30 psig @ SAT (2.1 Barg @ SAT). Valve must be in the full open during the SIP pro ce dure. C. Hose-Down Cleaning: 1. Standard Model SCV-S control valve units supplied with I/P positioners are NOT de signed to allow hose-down wash ing of the unit s ex te ri or. D. Instrument Air Supply - IAS: 1. For Model SCV-S with a positioner rec om mend using cryogenically pro duced nitrogen gas, or oil-free com pressed air des ic cant dried to -40 F(-40 C) dew point, fil tered to 10 mi crons or less as the IAS source. 2. All exhaust/vent air utilized by the Model SCV-S unit enters the ambient en vi ron ment. SECTION IV IV. INSTALLATION A. Orientation: 1. Standard orientation is with the yoke with position indicator plate and valve body outlet port in same plane. If an alternate ar range ment is necessary, loosen yoke nut (8) se cur ing yoke (3) to valve bonnet (2) ap prox i mate ly three revolutions. Rotate actuator assembly (AA) to de sired po si tion with re spect to body as sem bly (BA). Re-tighten yoke nut (8) to 85 ft-# (115 N M). NOTE: This pro ce dure can be done in-line. 2. Valve body must be installed in a horizontal or vertical plane where the outlet connection flow direction is down wards or horizontal. Failure to comply will cause the self-draining of the internal passages to be nullified, allowing CIP clean ing/flushing fluids to be ponded. See Figure 1. Straight Pattern HORIZONTAL OUTLET VERTICAL DOWN OUTLET Angle Pattern Figure 1: Installation Orientation 2
V. MAINTENANCE A. General: WARNING SYSTEM UNDER PRESSURE. Prior to per form ing any body disassembly or removal for maintenance, in spec tion or cleaning, isolate the valve body from the system and relieve all pressure. Failure to do so could result in personal injury. 1. Maintenance procedures hereinafter are based upon removal of the control valve unit from the piping system where installed. 2. Owner should refer to their pro ce dures for re mov al, handling and cleaning of nonre us able parts, i.e. gaskets, diaphragm, etc. SECTION V 8. Hereafter, whenever text has the fol low ing no ta tion, (Note RP.), the fol low ing text is to be applied: For ATO-FC reverse action units, re lease all tem po rary air pressure. B. Separation of Body/Actuator with Std Threaded Stem: NOTE: For units with Opt-68 Quick Dis con nect Stem proceed to Section V.C. See Fig. 2. 1. Secure body (1) into a vise with the actuator as sem bly (AA) in the upwards orientation. Place matchmarks between the yoke (3), bonnet (2), Tri-Clamp (4), and body (1) to assist in final ori en ta tion when the body is dis as sem bled and/or the actuator removed. 3. Valves supplied from the factory use a light coat of Emhart Bostic White Food Grade "NEVER_SEEZ" or equivalent on seals and threads. 4. Reference Figures 2 through 6 for iden ti fi ca tion of item numbers. 5. All item numbers with respect to body as sem bly (BA) will be in parentheses and not un der scored; i.e. (1). All item numbers with respect to the actuator assembly (AA) and positioner will be in parentheses and un der scored; i.e. (3). Reference with respect to the po si tion er is in double parentheses; i.e. ((AP)). 6. Special care must be exhibited when ro tat ing the stem (3,10) of the valve to not mar that portion of the surface of the stem where it contacts with the seal o-rings (9). To rotate the stem (3,10), use the jam nuts (17) or grasp stem with soft-jawed pliers. NOTE: When using the jam nuts to rotate the stem, use the upper jam nut to rotate the stem CW, and the lower jam nut to rotate the stem CCW, when viewed from above valve stem. 7. Hereafter, whenever text has the fol low ing no ta tion, (Note PA.), the fol low ing text is to be ap plied; For ATO-FC reverse action units, connect a temporary air source to the actuator and pres sur ize to a level suf fi cient to initiate travel to ap prox i mate ly mid-stroke. 2. Using an overhead hoist, rig the actuator as sem bly (AA) for a vertical lift. Remove slack from rigging. 3. (Note PA.) Rotate yoke nut (8), CCW (viewed from above) ap prox i mate ly 2 rev o lu tions. Secure the ac tu a tor stem (6). Loose jam nuts (17) by rotating CW one-at-a-time to base of stem (3) threads. 4. Fully loosen any accessory devices that are connected to the stem (3,6) such as accessory plate ((AP)) for positioner. (Note RP.) NOTE: To fully disengage actuator stem (6) from the stem (3) is a two-step pro ce dure. Be aware of the valve s stroke length as in di cat ed on the name plate (40) before be gin ning dis en gage ment. During the dis en gage ment, mea sure the dis tance ex tend ed, and stay at least 1/8" (3 mm) away from the full stroke length. Count and record the number of rev o lu tions for each step in the box below: No. of revolutions to disengage plug/stem from actuator stem: Step A. Step B. TOTAL: 5. For ATO-FC Reverse Action Units: a. (Note PA.) b. Step A. Rotate stem (3) CW (viewed from above) to disengage the ac tu a tor 3
4 stem (6) from the plug/stem (3), while holding the actuator stem (6). Record the num ber of plug/stem rev o lu tions for Step A above. When the dis en gage ment reach es about 50% of full stroke trav el Step A is com plet ed. (Note RP). c. Step B. Support the actuator as sem bly (AA) from above. Fully loosen yoke nut (8). Lift the actuator as sem bly (AA) up wards ap prox i mate ly 1/4"-3/8" (6-8 mm). Again, rotate plug/ stem (3) CW (viewed from above) to dis en gage the ac tu a tor stem (6) from the plug/stem (3) while holding the ac tu a tor stem (6). Record the number of plug/stem rev o lu tions for Step B above. This should allow the stems (6) (3) to fully dis en gage. NOTE: Take notice of the parts dan gling loosely about the stem (3), the order of their lo ca tion and their proper orientation. d. Fully raise the actuator assembly (AA) from the valve body assembly (BA). Re move cautiously to prevent dan gling parts - indicating washer (16), ac ces so ry plate ((AP)), yoke nut (8) - from fall ing. 6. For ATC-FO Direct Action Units: a. Step A. Rotate plug/stem (3) CW (viewed from above) to disengage the ac tu a tor stem (6). Do not rotate the plug (3) into the seat (11). Record the number of stem (3) rev o lu tions for Step A. When the dis en gage ment reach es about 75% of full stroke travel, Step A. is com plet ed. b. Step B. Support the actuator as sem bly (AA) from above. Fully loosen yoke nut (8) and remove. Lift the actuator as sem bly (AA) upwards ap prox i mate ly 1/4" - 3/8" (6-8 mm). Again, rotate plug/stem (3) CW (viewed from above) to dis en gage the ac tu a tor stem (6) from the plug/stem, while holding the actuator stem. Record the number of plug/stem rev o lu tions for Step B. This should allow the stems (6) (3) to fully disengage. NOTE: Take notice of the parts dangling loosely about the stem (3), the order of their lo ca tion and their proper orientation. c. Fully raise actuator assembly (AA) from the valve body assembly (BA). Re move cau tious ly to prevent dan gling parts indicating washer (16), ac ces so ry plate ((AP)), yoke nut (8) - from falling. C. Separation of Body/Actuator with Opt-68 Quick Disconnect Stem: 1. Place body assembly (BA) into a vise with the actuator as sem bly (AA) in the upwards position. 2. Place matchmarks between the yoke (3), bonnet (2), Tri-Clamp (4), and body (1) to assist during re-assembly. 3. Using an overhead hoist, rig the actuator as sem bly (AA) for a vertical lift. Remove slack from rigging. 4. Rotate yoke nut (8), (turning CCW viewed from above actuator) until fully dis-engaged. For ATO-FC (Reverse) Action Units Only: Connect a temporary air supply hose that has an ad just able airset with gauge to the ac tu a tor inlet to allow pres sur iza tion. Pressurize the actuator to upper limit of the bench range specified on the name plate (40). (NOTE: Pressure will lift the plug/ stem (10) away from the body's (1) integral seat until the plug is 100% open.). 42a 42b Figure 2: Opt.-68 Quick Disconnect 5. The valve stem (10)-to-actuator stem (6) assembly is a quick disconnect joint. Grasp stem (10) between thumb and fore fin ger of one hand. Grasp the lower collar (42b) between the thumb and fore fin ger of the other hand. Slide/push lower collar (42b) upwards. Stems (10) and (6) should uncouple and separate. NOTE: Take care to not drop the plug/stem (10) down wards into the body s (1) integral seat; lower slow ly to this po si tion. 16 17 10
6. Release temporary air pressure. 7. Lift actuator assembly (AA) up wards until able to swing out of the way and set down onto work surface. D. Body Disassembly: 1. Remove actuator assembly (AA) per Sec tion V.B.1-6 or V.C.1-7. 2. Remove clamp nuts (4.3), wash ers (4.4), bolts (4.2), and clamps (4.1). 4.2 4.3 disc(13). Place new seat disc on threaded end of plug and re-install in nut. Place stem on threaded end of plug and secure tight. Special care must be exhibited when ro tat ing the stem to not mar that portion of the surface of the stem where it contacts with the seal o-rings (9). Inspect the body (1) seating surface. If seating surface shows wear, re place the body. 2. Pick up bonnet (2) and using a thin-edged tool, remove both upper and lower stem seal rings (9) and discard used seal rings. 3. Clean all parts per owner s pro ce dures. A final rinse with ultra-clean water is rec om mend ed. 4.1 4.4 4.1 CAUTION Owner s cleaning solution must be com pat i ble with control valve s trim ma te ri als. F. Body Reassembly: Figure 3 : Clamp Orientation 3. Hold stem (3,10) securely, pull up wards, lifting bonnet (2) away from body (1). 4. Slide bonnet (2) up over end of plug/stem (3,10) and set both aside. 5. Remove gasket (7) from body (1) -to-bonnet (2) joint. Discard gasket (7). E. Trim Inspection and Replacement: 1. Inspect body (1), bonnet (2) and stem plug (3) or seat disc (13) for wear. If seating surfaces show signs of wear, proceed as follows: a. For metal seated plug construction, place lap ping com pound on seat ing sur fac es, re as sem ble body as sem bly (BA), and hand-lap the plug/stem (3) to re move minor seat wear. If hand-lapped, both the body (1) and plug/stem (3) head will re quire care ful me chan i cal pol ish ing and me chan i cal buffing; chemical electropol ish ing may be required. b. For composition seated con struc tion, secure stem/plug assembly (10) in a soft-jawed vise (plug end down) using the flats on the nut (12). Rotate stem CCW to remove. Insert flat blade screwdriver into the slot in the end of the plug and rotate CW to remove plug (15) and seat 1. Place body (1) into vise ori ent ed for vertical plug/stem position. 2. Place new gasket (7) onto body (1) flange. 3. Lubricate O.D. of stem seals (9) and carefully insert new spring-as sist ed stem seal rings (9) back into the bon net s (2) grooves. "Open" face of both seal rings oriented downwards towards the plug head. (Detail "A") CAUTION Do not use any sharp-edged tool to install the lower and upper stem seal rings (9). 4. Lubricate I.D. of stem seals (9). Insert the upper end of the stem (3,10) through the bon net (2) and through both stem seal rings (9). 5. Set bonnet (2) with inserted plug/stem onto the flange of the body (1). Lower plug/stem until it touch es the body seat. Press down firmly on the stem (3, 10) up per end. 6. Re-position clamps (4.1), bolts (4.2), washers (4.4), and nuts (4.3) around the body (1) tobonnet (2) joint. Rotate clamp nuts (4.3) a few revolutions in an alternating pattern to hold clamp assembly Align matchmarks. Position both hands around the outside of the Tri- Clamp, push the clamp to wards the valve s center. Ensure proper alignment of body (1) 5
with bonnet (2) by checking OD of flanges. Finger-tighten clamp nuts (4.3). NOTE: Gap be tween clamp (4.1) halves should be equal in size. See Figure 3. 7. Wrench-tighten each clamp nut (4.3) in al ter nate one-half rev o lu tion increments. Final tight en clamp bolting (4.2)(4.3) to a 20 Ft-lbs (27 N-m) torque value. 8. Reinstall actuator assembly (AA) to body assembly (BA) per Section V.G. or V.H. G. Mounting - Actuator to Body Std Threaded Stem: 1. Place body assembly (BA) into a vise securely with the stem (3, 10) directed upwards. 2. Install jam nuts (17) on stem (3), rotate CW down to base of threads and secure together tight. 3. Using an overhead hoist, rig and lift actuator assembly (AA) above body assembly (BA). Lower actuator as sem bly (AA) down and over stem (3), so the upper end of the stem passes through lower opening of the yoke (3) and through yoke nut (8). 4. Reposition indicating washer (16) or accessory plate ((AP)) over end of stem. For ATO-FC Reverse Action Units: Connect a temporary air supply hose that has an ad just able airset with gauge to the actuator and pressurize the actuator to upper limit of the bench range specified on the name plate (40). For ATC-FO Direct Action Units: Not necessary to connect temporary air supply. 5. Continue to lower actuator assembly until it rest on the bonnet (2). Align actuator assembly (AA) and body assembly (BA) with matchmarks of V.B.1 pre vi ous. Place yoke nut (8) onto bonnet threads and hand tighten. 6. With hand, grasp and lift plug/stem (3) up to connect with ac tu a tor stem (6). Rotate valve stem CCW (viewed from above) to en gage w/ ac tu a tor stem (6). Use the total number of revs en gage ment recorded in Step V.B.5. or Step V.B.6. as the guide to control engagement of the stems (6) (3.1). NOTE: For ATO-FC Action may need to slowly decrease actuator pressure to allow stem and collar to engage. 7. Rotate upper jam nut (17) up underneath indicating washer (16) or accessory plate ((AP)) and secure tight. Rotate lower jam nut up underneath upper jam nut - snug. 8. Tighten yoke nut (8) to 85 ft-# (115 N-M). For ATO-FC (Reverse) Action Units Only: Release all pressure from the actuator. H. Mounting - Actuator to Body Opt-68 QDS: 1. Place body into a vise securely with the plug/ stem (10) directed upwards. 2. Using an overhead hoist, rig and lift actuator assembly (AA) above body assembly (BA). Lower actuator as sem bly (AA) down and over valve stem (10), so the upper end of the valve stem passes through lower opening of the yoke (3) and through yoke nut (8). For ATO-FC Reverse Action Units: Connect a temporary air supply hose that has an ad just able airset with gauge to the actuator and pressurize the actuator to upper limit of the bench range specified on the name plate (40). For ATC-FO Direct Action Units: Not necessary to connect temporary air supply. 3. Continue to lower actuator assembly until it rest on the bonnet (2). Align actuator assembly (AA) and body assembly (BA) with matchmarks of V.B.1 pre vi ous. Place yoke nut (8) onto bonnet threads and hand tighten. 4. Grasp stem (10) between thumb and forefinger of one hand. Grasp collar (42b) be tween thumb and forefinger of the oth er hand. Lift stem up and into the opening of the lower collar (42b). Slide/push the collar (42b) upwards while si mul ta neous ly lifting the plug/stem end into the quick disconnect (42) as sem bly. A click will be felt when the engagement is prop er; release the collar (42b). The lower lips of the collar (42b) and the ac tu a tor stem (6) assembly should align. Re lease the plug/ stem (10) to en sure en gage ment. NOTE: For ATO-FC Action may need to slowly decrease actuator pressure to allow stem and collar to engage. 5. Tighten yoke nut (8) to 85 ft-# (115 N-M) For ATO-FC (Reverse) Action Units Only: Release all pressure from the actuator. 6
VI. CALIBRATION A. General: 1. This section only covers cal i bra tion of the control valve with Actuator Model C27-C53. 2. Positioner, if in stalled, requires ref er ence to the spe cif ic positioner mod el IOM for prop er cal i bra tion pro ce dure. 3. All indicated items numbers that are with re spect to IOM-C27-C53 will be in pa ren the sis and un der scored; i.e. (20); those that reference the po si tion er IOM will be in double parentheses; i.e. ((AP)). All item numbers that are with respect to this are not un der scored; i.e. (3). B. Procedure - Reverse Action, ATO-FC: 1. Reference the name plate (40) at tached to the actuator yoke (3). De ter mine the bench set ting of the installed range springs (10) from the name plate (40). 2. Connect a temporary air supply with an in-line ad just able airset reg u la tor and gauge to the lower actuator con nec tion. DO NOT LOAD with any air pressure at this point. 3. To determine when stem/plug (3,10) begins to lift out of the seat, touch the stem with one finger. (Stem will begin to move when actuator pressure exceeds the spring load.) 4. Slowly pressurize the ac tu a tor to a pres sure equal to the lower pres sure level of the bench setting; i.e. for 5-15 psig (.34 1.03 Barg) range, set pressure at 5 psig (.34 Barg). Take note of pressure reading when the stem first begins to move. 5. If the loading pressure for the start of stem movement is below the lower end of the desired bench setting, then the com bined stem (3,10 & 6) length is too short. For Std Threaded Stem: a. Rotate both jam nuts (17) down to base of threads on stem (3) and tighten together. b. Increase pressure in the actuator to setting. c. Rotate upper jam nut CW to increase the combined stem length. DO NOT allow actuator stem (6) to rotate in the actuator. SECTION VI d. Rotate upper jam nut CCW to hold indicating washer (16) up against stem (6). e. Release all pressure from the actuator and repeat Step 4 previous. For Opt-68 QDS Stem: a. Rotate jam nuts (17) down to base of threads on upper collar (42a). b. Increase pressure in actuator to setting. c. Rotate upper collar (42a) CCW to increase the combined stem length. DO NOT allow actuator stem (6) to rotate in the actuator. d. Rotate upper jam nut CW to hold indicator washer (16) up against stem (6). e. Release all pressure from the actuator and repeat Step 4 previous. 6. If the loading pressure for the start of stem movement is above the lower end of the desired bench setting, then the com bined stem (10, 6) length is too long. For Std Threaded Stem: a. Rotate both jam nuts (17) down to base of threads on stem (3) and tighten together. b. Increase pressure in the actuator to set. c. Rotate lower jam nut CCW to shorten the combined stem length. DO NOT allow actuator stem (6) to rotate in the actuator. d. Rotate upper jam nut CCW to hold indicating washer (16) up against stem (6). e. Release all pressure from the actuator and repeat Step 4 previous. For Opt-68 QDS Stem: a. Rotate jam nuts (17) down to base of threads on upper collar (42a). b. Increase pressure in actuator to setting. c. Rotate upper collar (42a) CW to shorten the combined stem length. DO NOT allow actuator stem (6) to rotate in the actuator. d. Rotate upper jam nut CW to hold indicator washer (16) up against stem (6). e. Release all pressure from the actuator and repeat Step 4 previous. 7. After the opening set point pressure has been established, rotate lower jam nut (17) CW up tight under the upper jam nut. 7
8. Release all pressure from the actuator. 9. Observe the location of the in di ca ting washer (16) to the "C" mark on the in di ca tor plate (23), mak ing sure to use the top edge of the in di ca ting washer (16) as the ref er ence point. Adjust indicator plate as needed. 10. Slowly increase the pressure in the actuator until the indicating washer (16) is in alignment with the "O" mark on the indicator plate. 11. To limit the up travel at the desired stroke length, rotate the travel stop nut (52) CW and secure to bottom of attachment hub (4). NOTE: Secure the actuator stem (6) by the flats when rotating the travel stop nut. NOTE: "Stroke" length is indicated on the nameplate (40), and is the distance between the "C" and "O" marks of the indicator plate (23). NOTE: The proper calibration of the actuator / valve unit will occur when at the lower pressure level of bench setting, the valve plug (3) will just begin to travel from the "C" position. At the upper level of the bench setting, the actuator pressure should be within ±8% of the upper bench range for the desired stroke length. 12. Release all pressure from actuator. C. Procedure - Direct Action, ATC-FO: 1. Reference the nameplate (40) attached to the actuator yoke (3). Determine the bench set ting of the installed range springs (10) from the nameplate (40). 2. Connect a temporary air supply with an in-line ad just able airset regulator and gauge to the upper actuator con nec tion. DO NOT LOAD with any air pressure at this point. 3. To determine when stem/plug (3) makes contact with the seat and travel stops, touch the stem with one finger. (Stem movement will stop when the plug engages the seat.) 4. Slowly pressurize the ac tu a tor to a pres sure equal to the upper pres sure lev el of the benchsetting; i.e. for a 5-15 psig (.34-1.0 Barg) range, set pressure at 15 psig (1.0 Barg). Take note of the pressure reading when stem travel actually stops. 5. If the loading pressure, when stem movement stops, is below the upper end of the desired bench setting, then the com bined stem (3,10, & 6) length is too long. For Std Threaded Stem: a. Rotate both jam nuts (17) down to base of threads on stem (3) and tighten together. b. Decrease pressure in the actuator to setting. c. Rotate lower jam nut CCW to shorten the combined stem length. DO NOT allow actuator stem (6) to rotate in the actuator. d. Rotate upper jam nut CW to hold indicating washer (16) up against stem (6). e. Release all pressure from the actuator and repeat Step 4 previous. For Opt-68 QDS Stem: a. Rotate jam nuts (17) down to base of threads on upper coupling (42a). b. Decrease pressure in the actuator to setting. c. Rotate upper coupling (42a) CW to shorten the combined stem length. DO NOT allow actuator stem (6) to rotate in the actuator. d. Rotate upper jam nut CW to hold indicator washer (16) up against stem (6). e. Release all pressure from the actuator and repeat Step 4 previous. 6. If the loading pressure, when stem movement stops, is above the upper end of the desired bench setting, then the com bined stem (3,10 & 6) length is too short. For Std Threaded Stem: a. Rotate both jam nuts (17) down to base of threads on stem (3) and tighten together. b. Decrease pressure in the actuator to setting. c. Rotate upper jam nut CW to increase the combined stem length. DO NOT allow actuator stem (6) to rotate in the actuator. d. Rotate upper jam nut CCW to hold indicating washer (16) up against stem (6). e. Release all pressure from the actuator and repeat Step 4 previous. For Opt-68 QDS Stem: a. Rotate jam nuts (17) down to base of threads on upper coupling (42a). b. Decrease pressure in the actuator to setting. 8
c. Rotate upper coupling (42a) CCW to increase the combined stem length. DO NOT allow actuator stem (6) to rotate in the actuator. d. Rotate upper jam nut CW to hold indicator washer (16) up against stem (6). e. Release all pressure from the actuator and repeat Step 4 previous. 7. After the closed- set point pressure has been established, rotate lower jam nut (17) CW up tight under the upper jam nut. 8. Increase pressure in the actuator to the upper pressure level of the bench setting. 9. Observe the location of the in di ca ting washer (16) to the "C" mark on the in di ca tor plate (23), mak ing sure to use the top edge of the in di ca ting washer (16) as the ref er ence point. Adjust indicator plate as needed. 10. Slowly decrease air pressure in actuator until indicating washer (16) is in alignment with the O mark on the indicator plate (23) 11. To limit the up travel at the desired stroke length, rotate the travel stop nut (52) CW and secure to bottom of attachment hub (4). NOTE: Secure the actuator stem (6) by the flats when rotating the travel stop nut. NOTE: "Stroke" length is indicated on the nameplate (40), and is the distance between the "C" and "O" marks of the indicator plate (23). NOTE: The proper calibration of the actuator / valve unit will occur when at the upper pressure level of bench setting, the valve plug (3) will be in the "C" position. At the lower level of the bench setting, the actuator pressure should be within ±8% of the lower bench range for the designed stroke length. 12. Release all pressure from actuator. 9
1. Unit can not pass enough flow. 10 VII. TROUBLE SHOOTING GUIDE Possible Cause Remedy A. Sizing data not correct; valve undersized. A1. Check actual pressures, temperature, and flow rates against the variables used for sizing. Recalculate CV Required. A2. Replace unit with larger body size. B. Obstruction at inlet. B. Remove valve and inspect line for blockage. C. Insufficient valve travel. C1. Verify full travel. C2. Verify correct IAS pressure. 2. Unit can not control steadily at low flow rates. Possible Cause Remedy A. Sizing data not correct; valve oversized. A1. Check actual pressures, temperature and flow rates against the variables used. A2. Replace full port body with reduced port body. B. Obstruction at inlet. B. Remove valve from line and inspect for something causing blockage. C. Too short of stroke C. Remove unit and calibrate. D. Excess pressure drop. D1. Check actuator bench setting; re-calibrate as required. D2. Check design pressures against actual pressures. Replace low bench set range springs with higher bench set range springs. E. Insuffi cient IAS pressure. E. Provide required level of IAS pressure. F. Incorrect flow direction. F. Verify flow with arrow cast on body; FTO 3. Valve body leaking at clamped end connection joints. Possible Cause Remedy A. Excess pressure levels. A. Check actual pressures against those indicated in Technical Bulletin. Reduce pressures as necessary. B. Loose clamp. B. Remove valve from service. Disassemble and clean. Reassemble and properly tighten all clamps at reinstallation. C. Excessive piping stress. C. Place hanger on control valve unit. D. Improper pipe alignment. D. Re-do piping properly. 4. Fluid leakage at bonnet or at upper stem seal ring. Possible Cause Remedy A. Gasket failure. A1. Remove body, disassemble, remove old gasket. Install new gasket, new stem seals, reassemble and reinstall. A2. Seal ring failure. B. Overheating B. Ensure that max. operating temperature of 366 F (186 C) is not exceeded. C. Stem seal failure C1. Worn stem seals. Replace seals and gasket. C2. Pitted stem, worn stem. Replace plug/stem, seals and gasket. 5. Inadequate valve shutoff. SEC TION VII Possible Cause Remedy A. Permanent "tracks" where seating occurs. A1. Relap body seat and plug (metal seat). A2. Replace body and plug or comp. seat disc. B. Excess valve pressure drop. B. Reduce valve's shutoff pressure drop. C. Insufficient IAS pressure. C. Provide required level of IAS pressure. D. Obstruction at seat. D. Remove body and inspect for obstruction. E. Improper calibration. E. Recalibrate positioner and valve stroke. F. Improper actuator bench set range. F. Disassemble actuator and change to stiffer range springs. Reinstall and increase IAS to proper level.
6. Unit will not operate. Possible Cause Remedy A. IAS is off. A. Turn on the IAS and set at proper level. B. Faulty positioner. B. Service positioner or replace. C. Improper positioner action. C. Switch positioner to proper action unit. D. Actuator has a leak. D. Manually load actuator to test for pressure integrity. Replace diaphragm and O-ring if either is leaking. 7. Instability. Possible Cause Remedy A. Insufficient dampening. A. Recalibrate and set dampening adjustment of positioner. B. Flow conditions. B. Reduce disturbances in fluid flow stream. SECTION VIII VIII. ORDERING INFORMATION NEW REPLACEMENT UNIT vs PARTS "KIT" FOR FIELD REPAIR To obtain a quotation or place an order, please retrieve the Serial Number and Product Code that was stamped on the metal name plate and attached to the unit. This information can also be found on the Bill of Material ("BOM"), a parts list that was provided when unit was originally shipped. (Serial Number typically 6 digits). Product Code typical format as follows: (last digit is alpha character that refl ects revision level for the product). 7 NEW REPLACEMENT UNIT: Contact your local Cashco, Inc., Sales Rep re sen ta tive with the Serial Number and Product code. With this information they can provide a quotation for a new unit including a complete description, price and availability. CAUTION Do not attempt to alter the original construction of any unit without assistance and approval from the factory. All purposed changes will require a new name plate with appropriate ratings and new product code to accommodate the recommended part(s) changes. PARTS "KIT" for FIELD REPAIR: Contact your local Cashco, Inc., Sales Rep re sen ta tive with the Serial Number and Product code. Identify the parts and the quantity required to repair the unit from the "BOM" sheet that was provided when unit was originally shipped. NOTE: Those part numbers that have a quantity indicated under "Spare Parts" in column "A reflect minimum parts required for inspection and rebuild, - "Soft Goods Kit". Those in column B include minimum trim replacement parts needed plus those "Soft Goods" parts from column "A". If the "BOM" is not available, refer to the crosssectional drawings included in this manual for part identification and selection. A Local Sales Representative will provide quotation for appropriate Kit Number, Price and Availability. The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. We reserve the right to modify or improve the designs or specifi cations of such product at any time without notice. Cashco, Inc. does not assume responsibility for the selection, use or maintenance of any product. Responsibility for proper selection, use and maintenance of any Cashco, Inc. product remains solely with the purchaser. 11
OPT-68 Detail A FIGURE 4: Straight-Globe Body Assembly (BA), Metal Seat REPLACEMENT ITEM NO. DESCRIPTION PARTS 1 Body 2 Bonnet 3 Stem/Metal Plug * 4 Tri-Clover Clamp 7 Gasket * 8 Yoke Nut 9 Seal Rings (2 req'd.) * 10 Stem/Composition Seat * 11 Gasket * 12 Seat Nut * 13 Seat Disc * 14 Pin * 15 Plug * 16 Indicating Washer 17 Stem Jam Nuts FIGURE 6: Composition seat with OPT-68 Quick Disconnect ITEMS NOT SHOWN ITEM NO. DESCRIPTION 5 Flow Arrow Tag 6 Drive Screw 42 See Figure 3 FIGURE 5: Angle-Globe Body Assembly (BA), Metal Seat 12
ATEX 94/9/EC: Explosive Atmospheres and Cashco Inc. Regulators NOTICE Only for Product Codes wherein hazard category ATEX has been selected. These valves satisfy the safety conditions according to EN 13463-1 and EN 13463-5 for equipment group IIG 2 c. Caution: Because the actual maximum temperature depends not on the equipment itself, but upon the fluid temperature, a single temperature class or temperature cannot be marked by the manufacturer. Specific Precaution to Installer: Electrical grounding of valve must occur to minimize risk of effective electrical discharges. Specific Precaution to Installer: Atmosphere vent holes should be plugged to further minimize the risk of explosion. Specific Precaution to Maintenance: The Valve Body/ Housing must be regularly cleaned to prevent buildup of dust deposits. Specific Precaution to Maintenance: Conduct periodic Continuity Check between Valve Body/ Housing and Tank to minimize risk of electrical discharges. Attention: When repairing or altering explosion-protected equipment, national regulations must be adhered to. For maintenance and repairs involving parts, use only manufacturer's original parts. ATEX requires that all components and equipment be evaluated. Cashco pressure regulators are considered components. Based on the ATEX Directive, Cashco considers the location where the pressure regulators are installed to be classified Equipment-group II, Category 3 because flammable gases would only be present for a short period of time in the event of a leak. It is possible that the location could be classified Equipment-group II, Category 2 if a leak is likely to occur. Please note that the system owner, not Cashco, is responsible for determining the classification of a particular installation. Product Assessment Cashco performed a conformity assessment and risk analysis of its pressure regulator and control valve models and their common options, with respect to the Essential Health and Safety Requirements in Annex II of the ATEX directive. The details of the assessment in terms of the individual Essential Health and Safety Requirements, are listed in Table 1. Table 2 lists all of the models and options that were evaluated and along with their evaluation. Models and options not listed in Table 2 should be assumed to not have been evaluated and therefore should not be selected for use in a potentially explosive environment until they have been evaluated. Standard default options for each listed model were evaluated even if they were not explicitly listed as a separate option in the table. Not all options listed in the tables are available to all models listed in the tables. Individual TB s must be referenced for actual options. When specifying a regulator that is to be used in a potentially explosive environment one must review the evaluations in Table 1 and 2 for the specific model and each and every option that is being specified, in order to determine the complete assessment for the unit. A summary of the models and options found to have an impact on ATEX assessment due to potential ignition sources or other concerns from the ATEX Essential Health and Safety Requirements, are listed below. 1. The plastic knob used as standard on some models, (P1, P2, P3, P4, P5, P7, 3381, 4381, 1171, and 2171) is a potential ignition source due to static electricity. To demonstrate otherwise, the knob must be tested to determine if a transferred charge is below the acceptable values in IEC 60079-0 Section 26.14 (See items 25, 27, and 28 in Appendix A). Until the plastic knob has been shown to be acceptable, then either the metal knob option, or a preset outlet pressure option is required to eliminate this ignition source (See items 45 and 64 in Tables). 2. The pressure gauges offered as options on a few of the regulator models (DA s, P1-7, D, 764, 521), use a plastic polycarbonate window that is a potential ignition source due to static electricity. To demonstrate that the gauges are not a potential source of ignition, the gauges would need to be tested to determine if a transferred charge is below the acceptable values in IEC 60079-0 Section 26.14 or the pressure gauge supplier must provide documentation indicating the gauge is compliant with the ATEX Directive (See items 26, 27, and 28 in Appendix A). Until compliance is determined, regulators should not be ordered with pressure gauges for use in potentially explosive environments. 13
3. Tied diaphragm regulators with outlet ranges greater than 100 psig should be preset to minimize the risk that improper operation might lead to an outboard leak and a potentially explosive atmosphere (See item 6 in Table 1). 4. Regulators must be ordered with the non-relieving option (instead of the self-relieving option) if the process gas they are to be used with is hazardous (flammable, toxic, etc.). The self-relieving option vents process gas through the regulator cap directly into the atmosphere while the non-relieving option does not. Using regulator with the self- relieving option in a flammable gas system could create an explosive atmosphere in the vicinity of the regulator. 5. Regulators with customer supplied parts are to be assumed to not have been evaluated with regard to ATEX and thus are not to be used in a potentially explosive environment unless a documented evaluation for the specific customer supplied parts in question has been made. Refer to Table 1 for all models and options that have been evaluated. Product Usage A summary of ATEX related usage issues that were found in the assessment are listed below. 1. Pressure regulators and control valves must be grounded (earthed) to prevent static charge build-up due to the flowing media. The regulator can be grounded through any mounting holes on the body with metal to metal contact or the system piping can be grounded and electrical continuity verified through the body metal seal connections. Grounding of the regulator should follow the same requirements for the piping system. Also see item 30 in Table 1. 2. The system designer and users must take precautions to prevent rapid system pressurization which may raise surface temperatures of system components and tubing due to adiabatic compression of the system gas. 3. Heating systems installed by the user could possibly increase the surface temperature and must be evaluated by the user for compliance with the ATEX Directive. User installation of heating systems applied to the regulator body or system piping that affects the surface temperature of the pressure regulator is outside the scope of this declaration and is the responsibility of the user. 4. The Joule-Thomson effect may cause process gases to rise in temperature as they expand going through a regulator. This could raise the external surface temperature of the regulator body and downstream piping creating a potential source of ignition. Whether the Joule-Thomson effect leads to heating or cooling of the process gas depends on the process gas and the inlet and outlet pressures. The system designer is responsible for determining whether the process gas temperature may rise under any operating conditions. If a process gas temperature rise is possible under operating conditions, then the system designer must investigate whether the regulator body and downstream piping may increase in temperature enough to create a potential source of ignition. The process gas expansion is typically modeled as a constant enthalpy throttling process for determining the temperature change. A Mollier diagram (Pressure Enthalpy diagram with constant temperature, density, & entropy contours) or a Temperature Entropy diagram with constant enthalpy lines, for the process gas, can be used to determine the temperature change. Helium and hydrogen are two gases that typically increase in temperature when expanding across a regulator. Other gases may increase in temperature at sufficiently high pressures. Product Declaration If the above issues are addressed by selecting options that do not have potential sources of ignition, avoiding options that have not been assessed, and by taking the proper usage issue precautions, then Cashco regulators can be considered to be a mechanical device that does not have its own source of ignition and thus falls outside the scope of the ATEX directive. Cashco, Inc. P.O. Box 6 Ellsworth, KS 67439-0006 PH (785) 472-4461 Fax. # (785) 472-3539 www.cashco.com email: sales@cashco.com Printed in U.S.A. SCV-S-IOM 14 Cashco GmbH Handwerkerstrasse 15 15366 Hoppegarten, Germany PH +49 3342 30968 0 Fax. No. +49 3342 30968 29 www.cashco.com email: germany@cashco.com Cashco do Brasil, Ltda. Al.Venus, 340 Indaiatuba - Sao Paulo, Brazil PH +55 11 99677 7177 Fax. No. www.cashco.com email: brazil@cashco.com